JP2002265803A - Porous cured product and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a porous cured product containing organic fibrous powders such as wood flour, wood chips, sawdust, chaff powder and bagasse powder as fillers maintaining characteristics of porous materials having a humidity control function and the like, maintaining characteristics of porous cured product comprising cured particle dispersion having fine open pores and obtained by combining resin particles obtained by curing the O/W aqueous dispersion and excellent in physical properties such as mechanical strength. SOLUTION: This porous cured product comprises a cured particle assembly having open pores, reinforced with organic fibrous materials and obtained by combining resin particles obtained by curing O/W type aqueous dispersoid comprising a thermosetting resin dispersed with organic fibrous powders therein, and the other objective method for producing the porous cured product is provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a porous cured product having continuous pores in which resin particles obtained by curing an O / W type aqueous dispersion composed of a thermosetting resin are bonded. More specifically, a cured particle aggregate reinforced with organic fibers having continuous pores by bonding resin particles obtained by curing an O / W type aqueous dispersion composed of a thermosetting resin in which organic fiber powder is dispersed. And a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, organic fibrous powders such as wood flour, wood chips, and rice husk flour have been used as fillers for thermosetting resins because they are lightweight and inexpensive. When these organic fiber powders are used as a filler, the organic fiber powder and a liquid or powdery thermosetting resin are mixed and kneaded to form a compound to form a molding material. Alternatively, an organic fibrous powder is mixed with a liquid thermosetting resin, molded and cured to form a molded product such as a laminated board. Conventionally, when an organic fiber powder is used as a filler, a molded article having high mechanical strength and the like can be obtained by sufficiently impregnating the filler with a resin. However, in a molded article using such a conventional organic fiber powder as a filler, resin is also filled in fine voids such as a conduit portion of the organic fiber powder filler. The moisture control function and the heat insulating property of the molded article are lost, and in such a molded article, the humidity control function and the heat insulating function of the organic fiber are not utilized, and the void portion is filled with the resin and the specific gravity is high. It is a molded product.

On the other hand, the present inventor has proposed an O / W type thermosetting resin aqueous dispersion in which resin particles are uniformly dispersed in an aqueous phase obtained by mixing a radical polymerization type thermosetting resin and water. A porous cured product composed of an aggregate of cured particles having fine continuous pores combined with spherical resin particles obtained by curing the same was found. This porous cured product is a porous material having fine continuous pores of 1 μm or less, and is a material suitable for use as, for example, a microfiltration membrane, a pottery frame material, etc. by utilizing its characteristics. However, a porous cured product obtained by curing the O / W type thermosetting resin aqueous dispersion has a lower strength than a normal cured product obtained by curing a thermosetting resin.
When used for filtration membranes, pottery forms, and the like, they have the drawback of short product life.

[0004]

DISCLOSURE OF THE INVENTION In view of the above circumstances, the present invention requires that organic fiber powder such as wood powder, wood chip, saw chip, rice husk powder and bagasse powder be a porous material having a humidity control function and the like. It is used as a filler while maintaining the features of the above, and is a cured particle dispersion having fine continuous pores combined with spherical resin particles obtained by curing an O / W type thermosetting resin aqueous dispersion. Maintain the characteristics of the porous cured product,
It is another object of the present invention to provide a porous cured material having excellent physical properties such as mechanical strength.

[0005] The present inventor has repeatedly studied from various viewpoints,
By dispersing and hardening organic fiber powder such as wood flour, wood dust, sawdust, rice husk powder, bagasse powder, or wood chips in an aqueous O / W-type thermosetting resin dispersion, the organic fiber is porous. The present inventors have found that a high-strength, lightweight, porous cured product can be obtained while maintaining the humidity control function and the heat insulating property, and completed the present invention.

[0006]

That is, the present invention provides:
(1) A resin particle obtained by curing an aqueous O / W type thermosetting resin dispersion in which an organic fiber powder is dispersed is bonded to form a cured particle aggregate reinforced with organic fibers having continuous pores. It relates to a porous cured product.

(2) An aqueous O / W type thermosetting resin dispersion is prepared by mixing a liquid radical polymerization type thermosetting resin and water in a weight ratio of 90:10 to 60:40, and the resin particles are mixed with water. The above (1), which is an O / W type aqueous dispersion uniformly dispersed in a phase
The present invention relates to the porous cured product described above.

(3) O / W in which organic fiber powder is dispersed
Type thermosetting resin aqueous dispersion is composed of organic fiber powder and O / W
Mold thermosetting resin aqueous dispersion in a weight ratio of 5:95 to 5: 5.
The present invention relates to the porous cured product according to the above (1) or (2), which is an O / W aqueous dispersion mixed at 0:50.

(4) The organic fiber powder is wood powder, rice husk powder,
The present invention relates to the porous cured product according to (1) to (3), which is at least one selected from wood chips, saw chips, bagasse powder, and wood chips.

(5) The liquid radical polymerization type thermosetting resin is at least one selected from a liquid unsaturated polyester resin, a liquid epoxy (meth) acrylate resin, a liquid urethane (meth) acrylate resin, and a liquid (meth) acryl resin. The present invention relates to one kind of the porous cured product according to any of the above (1) to (4).

The present invention further provides (6) an aqueous O / W type thermosetting resin dispersion in which a liquid radical polymerization type thermosetting resin is mixed with water and resin particles are uniformly dispersed in an aqueous phase. The organic fiber powder is mixed and dispersed, and the organic fiber powder dispersion O /
The present invention relates to a method for producing a porous cured product, which comprises curing a W-type thermosetting resin aqueous dispersion at ordinary temperature or under heating.

(7) O / W in which organic fiber powder is dispersed
(6) wherein the aqueous thermosetting resin dispersion is cured at room temperature or under heating in the presence of a reinforcing material.
The present invention also relates to a method for producing the described porous cured product.

[0013]

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an aqueous dispersion of an O / W type thermosetting resin obtained by mixing a liquid radical polymerization type thermosetting resin with water and uniformly dispersing the resin particles in an aqueous phase. An organic fiber powder is mixed and dispersed in a body (hereinafter, simply referred to as an “O / W type aqueous dispersion”), and the O / W
W-type aqueous dispersion, in the presence of a reinforcing material, if necessary, at room temperature or under heating, obtained from a cured particle aggregate reinforced with organic fibers having continuous pores combined with resin particles obtained by curing at an excellent temperature It relates to a porous cured product having strength.

The present inventor has proposed that wood flour, wood dust, sawdust, rice husk flour,
Focusing on the fact that organic fiber powder such as bagasse powder or wood chips is hydrophilic and has better wettability with water than oily resin, the organic fiber powder is dispersed in an O / W type aqueous dispersion. In this case, first, water is adsorbed and water is filled in the fibrous fine conduit and voids, and the substantially spherical fine particles dispersed in oily water contact the surface of the organic fibrous powder. However, the spherical shape is broken by the interfacial tension with the organic fiber powder, and the resin component adheres to the surface of the organic fiber powder. As a result, the resin is not filled in the fibrous conduit. The cured product obtained by curing the O / W type aqueous dispersion in which the resin component is adhered to the organic fiber powder maintains the porosity, and the effect of the interfacial tension between the organic fiber and the thermosetting resin. As a result, it was confirmed that the contact area between the resin particles, in other words, the adhesion area increased, and the mechanical strength also improved.

O / W in which the organic fiber powder of the present invention is dispersed
The porous cured product obtained by curing the aqueous dispersion of the mold is a cured product in which the spherical resin particles are combined to form a cured particle aggregate having fine continuous pores, and the strength is increased without impairing the porosity. When applied to wall materials, microfiltration membranes, pottery molds, etc., the life of the product can be extended. Further, by using an aqueous dispersion having functions such as antibacterial properties, antifungal properties and deodorizing properties as the O / W type aqueous dispersion used in the present invention, high strength with higher added value can be obtained. A porous cured product having the same can be obtained. Examples of the antibacterial agent imparting such a function include “NOVALON AGT330” and “NOVALON AG300” commercially available from Toa Gosei Co., Ltd.
For example, “Cavinon 800” and “Cavinon 900” commercially available from Toa Gosei Co., Ltd. can be mentioned. Examples of the deodorant include “Skemon NS80E” and “Skemon TNS2” also commercially available from Toa Gosei Co., Ltd.
00 ”and the like.

Examples of the organic fiber powder used in the present invention include pulverized materials such as wood flour, sawdust and wood chips, pulverized rice hulls, pulverized bagasse as sugarcane pomace, and the like.
Even if a relatively large pulverized powder such as wood chips is used in addition to the pulverized material, the strength of the porous cured product can be increased, and the desired effect can be achieved. The organic fibrous powder used in the present invention is in a powder form from the viewpoint of, for example, dispersibility with the O / W type aqueous dispersion and the porous nature of the organic fiber. Preferably
Usually, an average size of about 0.1 mm to 5.0 mm is used.

The method of imparting functions such as antibacterial property, antifungal property and deodorant property to the O / W type aqueous dispersion used in the present invention is usually carried out by adding a liquid radical polymerization type thermosetting resin to a liquid. In this method, a desired function-imparting agent is added and mixed, but it can also be imparted by using a material exhibiting antibacterial properties as a material component constituting the radical polymerization type thermosetting resin. For example, when producing an unsaturated polyester resin, a part of the dibasic acid to be used is changed to a dibasic acid containing a quaternary ammonium salt or a pyridinium salt capable of exhibiting antibacterial properties, and the antibacterial property is improved. The resulting unsaturated polyester resin can be obtained.

The liquid radical polymerization type thermosetting resin used in the present invention is a liquid unsaturated polyester resin, a liquid epoxy (meth) acrylate resin, a liquid urethane (meth) acrylate resin or a liquid (meth) acrylic resin (so-called Acrylic syrup) is used.

The liquid unsaturated polyester resin in the present invention comprises a polyhydric alcohol containing glycols as a main component, an α, β-unsaturated dibasic acid and / or an anhydride thereof, and if necessary, a saturated dibasic acid. And / or a liquid resin in which an unsaturated polyester obtained by polycondensation with an anhydride thereof is dissolved in a polymerizable monomer having an ethylenically unsaturated double bond such as styrene.

The above glycols include, for example, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, pentaerythritol, Examples thereof include pentaerythritol derivatives such as pentaerythritol dialiether, allyl glycidyl ether, hydrogenated bisphenol A, bisphenol A, bisphenol A derivatives, and the like.

Examples of the α, β-unsaturated dibasic acid and / or its anhydride include maleic acid or its anhydride, fumaric acid, itaconic acid and its anhydride, and the like. These can be used alone or in combination of two or more.

Examples of the saturated dibasic acid and / or its anhydride include, for example, phthalic anhydride, terephthalic acid, isophthalic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, endomethylenetetrahydrophthalic anhydride, adipic acid, sebacin Acid, tetrabromophthalic anhydride, heptonic acid, hexahydrophthalic anhydride, 1,3
-Cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid and the like. These can be used alone or in combination of two or more.

Examples of the polymerizable monomer having an ethylenically unsaturated double bond include vinyl monomers such as styrene, vinyltoluene, α-methylstyrene, vinyl acetate, methyl methacrylate, and ethyl methacrylate, and diallyl. Allyl monomers such as phthalate, diallyl isophthalate, triallyl isocyanurate, diallyl tetrabromophthalate, phenoxyethyl acrylate,
Examples thereof include 1,6-hexanediol acrylate, trimethylolpropane triacrylate, and 2-hydroxyethyl acrylate. These can be used alone or in combination of two or more. Of these, vinyl monomers such as styrene and vinyltoluene are generally used.

As the liquid epoxy (meth) acrylate resin in the present invention, an epoxy group having two or more glycidyl ether groups in one molecule is reacted with acrylic acid or methacrylic acid to obtain an epoxy group at the molecular terminal. Having epoxy (meth) acrylate resin,
A liquid resin dissolved in a polymerizable monomer having an ethylenic α, β-unsaturated double bond. Examples of the epoxy resin having two or more glycidyl ether groups in one molecule include bisphenol A, bisphenol F, bisphenol S and the like, or bisphenol type epoxy resins derived from these derivatives, bixylenol and bixylenol derived therefrom. Epoxy resins, biphenol-type epoxy resins from biphenol and its derivatives, or naphthalene-type epoxy resins from naphthalene and its derivatives, and epoxy resins such as novolak-type epoxy resins. These may be used alone or in combination of two or more. Can be used in combination. Ethylenic α,
As the polymerizable monomer having a β-unsaturated double bond, the same polymerizable monomer as used in the above-described unsaturated polyester resin can be used. The liquid epoxy acrylate or epoxy methacrylate resin is a liquid resin obtained by dissolving the above epoxy acrylate or epoxy methacrylate in a liquid polymerizable monomer such as styrene or diethylene glycol dimethacrylate.

The liquid urethane (meth) according to the present invention
The acrylate resin is prepared by reacting polyalcohol and / or polyester polyol and / or polyether polyol with diisocyanate to react the molecular terminal with isocyanate to form isocyanate, and reacting acrylate or methacrylate having an alcoholic hydroxyl group with this. Or a double bond of acrylate or methacrylate at the molecular terminal obtained by first reacting an acrylate or methacrylate having an alcoholic hydroxyl group with an isocyanate and a polyalcohol and / or polyester polyol and / or polyether polyol while leaving the isocyanate group. Urethane acrylate or urethane methacrylate having, for example, styrene, diethylene glycol dimethacrylate, etc. A liquid resin which is dissolved in the polymerizable monomer liquid. These can be used alone or in a mixture of two or more.

The liquid acrylic resin or methacrylic resin used in the present invention may be a methyl methacrylate copolymer comprising methyl methacrylate as a main component and partially copolymerizing another polymerizable monomer, or a methyl methacrylate copolymer. A liquid resin obtained by dissolving a copolymer in methyl methacrylate, which is usually called acrylic syrup. In order to make these liquid resins thermosetting, for example,
Polyfunctional methacrylate or acrylate monomers such as ethylene glycol dimethacrylate and diethylene glycol dimethacrylate are used in combination.

The O / W aqueous dispersion used in the present invention can be easily produced by mixing a liquid radically polymerizable thermosetting resin and water by a physical mixing means. Specifically, a predetermined amount of water is added to a liquid radically polymerizable thermosetting resin to which a curing agent and, if necessary, an accelerating agent are added, and a physical solution such as a dissolver (high-speed rotation mixer) or a homomixer is added. A stable aqueous dispersion can be obtained by mixing by a mixing means or ultrasonic irradiation. The water used is ion-exchanged water,
Any of distilled water and tap water may be used without any particular limitation.

The mixing ratio of the liquid radically polymerizable thermosetting resin and water is in the range of 90:10 to 60:40 by weight, preferably 85:15 to 70:30.
When the mixing ratio of water is higher than the above range, the surface of the organic fiber powder is completely covered with water, and the contact area with the resin is extremely reduced, and the strength is reduced. On the other hand, when the mixing ratio of water is smaller than the above range, the form of the aqueous dispersion becomes W / O type, or the resin or resin is filled in the conduit or void portion of the organic fiber to adjust the organic fiber. Not only is the wet function lost, but the specific gravity of the resulting product is increased and the advantage of light weight may be lost, which is not preferable.

In the present invention, the organic fiber powder and the O / W
The mixing ratio with the aqueous dispersion is 5:95 to 5 by weight.
0:50, preferably 10: 90-4.
0:60. If the mixing ratio of the organic fibrous powder is larger than the above range, the bonding between the organic fibrous powders becomes weak, and it is not possible to obtain a target porous cured product having sufficiently high strength. On the other hand, when the mixing ratio of the organic fiber powder is smaller than the above range, the reinforcing effect as a filler of the organic fiber powder is not exhibited, and the intended porous cured product having sufficient strength is obtained. Can not be.

The porous cured product reinforced with organic fibers of the present invention has continuous pores composed of a set of cured particles in which particles having organic fiber powder adhered are bonded to the surface of substantially spherical resin particles. It is a porous cured product. This porous cured product is a cured product reinforced with an organic fiber as a filler, and the pore size and pore size of the porous cured product obtained by the amount, type, shape, size, etc. of the organic fiber powder used. Rate depends on
For example, when wood flour is used as the organic fiber powder and the amount of wood flour is increased within the above range, the mixing ratio of the wood flour to the O / W type aqueous dispersion is from 15:85 by weight. When the mixing ratio of O is increased, the effective pore size increases, and wood flour and O
When the mixing ratio with the / W type aqueous dispersion was 40:60, the effective pore diameter was 100 μm. The same tendency is observed when other organic fiber powders are used. The porous cured product of the present invention generally has a porosity of 10 to 40% by volume and an effective pore diameter of 0.1% within the above-mentioned mixing ratio of the present invention.
1 to 200 μm. In the present invention, the porosity and the pore diameter are measured as follows.

(1) Porosity The weight of the cured product before and after drying was measured, and the specific gravity of water was set to 1.0, and the difference between the values [(weight before drying) − (weight after drying)] was calculated as the volume of the pore portion ( a). In addition, the dimensions of the cured product before drying are measured and the volume thereof is calculated as the total volume (b) of the cured product, and the porosity (X) is obtained from the following equation.

[0032]

X (%) = a / b × 100

(2) Porosity Diameter Porosity meter “Autopore III 94” manufactured by Shimadzu Corporation
Using 20 ", the average effective pore diameter is determined from the pressure and amount of mercury injected.

In the present invention, when the O / W type aqueous dispersion in which the organic fibrous powder is dispersed is cured, it may be at room temperature or under heating. After the curing, the cured product can be post-cured in the range of 40 to 120 ° C., if necessary.

The organic fibrous powder used in the present invention is not basically affected by the amount of water due to adsorption or water absorption. In order to obtain a porous hardened material while leaving more of the porous portion, it is not particularly limited, but is preferably 40 ° C to 120 ° C.
It is preferable to use one dried at a temperature of about 10 minutes to about 2 hours.

The O / W aqueous dispersion used in the present invention is used by adding a curing agent and, if necessary, an accelerator. The accelerator is previously added to the liquid radical polymerization type thermosetting resin. It is desirable to prepare an O / W type aqueous dispersion by addition. The curing agent is usually added at the time of use. When the curing agent is in the form of powder or paste and it takes time to dissolve uniformly in the resin, it is desirable to add the curing agent to the liquid radical polymerization thermosetting resin in advance to prepare an O / W type aqueous dispersion. . In that case, the accelerator is added when used for molding or the like.

As the curing agent used in the present invention, an organic peroxide is usually used. Representative examples of such a curing agent include ketone peroxides represented by methyl ethyl ketone peroxide and 1,1-bis (t-
(Hexylperoxy) peroxyketals represented by 3,3,5-trimethylcyclohexane, hydroperoxides represented by cumene hydroperoxide, dialkyl peroxides represented by dicumyl peroxide, benzoyl peroxide And peroxydicarbonates represented by bis (4-t-butylcyclohexyl) peroxydicarbonate, peroxybenzoates represented by t-butylperoxybenzoate, and the like. . Such a curing agent is usually used in an amount of 0.5 to 100 parts by weight of the liquid radical polymerization type thermosetting resin.
It is used in a range of 3.0 parts by weight, preferably 0.5 to
2.0 parts by weight are used.

The above accelerators include metal salts (metal soaps) of organic acids represented by cobalt naphthenate, tertiary amines such as N, N-dimethylaniline and N, N-dimethylparatoluidine, ferrocene and the like. An accelerator usually used for curing an unsaturated polyester resin at room temperature is used. These accelerators are preferably used in combination with a metal soap such as cobalt naphthenate when ketone peroxide or hydroperoxide is used as a curing agent, or 3 when the curing agent is diacyl peroxide.
A combination with a secondary amine is preferred, and when the curing agent is peroxycarbonate, a combination with ferrocene is preferred. As such an accelerator, the metal soap has a metal content of 6 parts by weight based on 100 parts by weight of the liquid radical polymerization type thermosetting resin.
%, And used in the range of 0.02 to 2.0 parts by weight, preferably 0.2 to 1.0 part by weight. Tertiary amines are liquid radical polymerization type thermosetting resins 1
It is used in the range of 0.05 to 1.0 part by weight, preferably 0.1 to 0.5 part by weight, per 100 parts by weight.

In preparing the O / W type aqueous dispersion of the present invention, a surfactant can be used if necessary.
Since the use of a surfactant can enhance the stability of the O / W aqueous dispersion of the present invention, the aqueous dispersion of the present invention is not used immediately after preparation, but is left as it is after being left for several days to obtain a cured product. In such a case, it is desirable to add a surfactant.

The surfactant used in the present invention includes:
Nonionic surfactants are desirable. Nonionic surfactants include (1) ester type, (2) ether type,
Any of (3) alkylphenol type, (4) sorbitan ester type, (5) polyoxyethylene sorbitan ester type, and (6) special nonionic type can be used. The addition amount of such a surfactant is used in the range of 0.1 to 10 parts by weight, preferably 0.5 to 2.0 parts by weight, based on 100 parts by weight of the liquid radical-curable thermosetting resin. Is done. When the amount of the surfactant is less than 0.1 part by weight, the effect of the addition is not exhibited, and when the amount exceeds 10 parts by weight, the water resistance may decrease, which is not preferable.

In order to further impart strength, durability and the like to the porous cured product of the present invention, a reinforcing material can be used as required. As such a reinforcing material, for example, synthetic fiber cloth such as chopped glass fiber, glass cloth, glass chopped strand mat, carbon cloth, aramid fiber, polyester fiber, acrylic fiber, polypropylene fiber, or synthetic fiber nonwoven fabric, rayon And nonwoven fabrics.

[0042]

EXAMPLES Next, the present invention will be described specifically with reference to examples, but the present invention is not limited to these examples.

Example 1 In a metal container having an inner diameter of 20 cm and a height of 30 cm, 600 g of an epoxy acrylate resin ("Neopol 8250" (specific gravity: 1.08), manufactured by Nippon Yupika Co., Ltd.) was weighed and used as a curing agent. 12 g of commercially available benzoyl peroxide having a concentration of 50% by weight (1 g of pure content per 100 g of resin) and 6 g of "Pluronic L-61" (polyoxyethylene propylene ether type, manufactured by Asahi Denka Kogyo KK) as a surfactant. Add and mix well while mixing slowly, then tap water 2
00 g (25 g for 75 g of resin), and the number of revolutions was 5000 rpm using a dissolver having an outer diameter of the blade of 4 cm.
and the mixture was stirred at a high speed for 5 minutes to obtain an O / W type aqueous dispersion. N, N-dimethylaniline 1.2 was added to the obtained aqueous dispersion.
g, and sufficiently dissolved, 250 g of fine rice husk powder was added to the aqueous dispersion, and the mixture was stirred and dispersed.
After pouring into a × 100 mm mold and degassing by applying vibration,
Cured for 3 hours at room temperature. After the curing, the cured product was taken out of the mold, left standing at room temperature for 24 hours, and dried to obtain a porous cured product comprising an aggregate of cured particles reinforced with organic fibers. The obtained cured product has a porosity of 30% by volume and an effective pore diameter of 1.2 μm.
Met. Table 1 shows the physical properties of the porous cured product such as bending strength, specific gravity, and shrinkage.

Example 2 In a metal container having an inner diameter of 20 cm and a height of 30 cm, a liquid unsaturated polyester resin ("Yupika 6" manufactured by Nippon Yupika Co., Ltd.) was used.
510 "(specific gravity 1.10)), 500 g of benzoyl peroxide (a pure content of 1 g based on 100 g of resin) having a concentration of 50% by weight as a curing agent, and" Pluronic L-61 "as a surfactant. After adding 10 g of water and mixing gently, 215 g of tap water (30 g per 70 g of resin) was added, and the mixture was stirred at a high speed of 5,000 rpm for 5 minutes using a dissolver having an outer diameter of the blade of 4 cm. A W-type aqueous dispersion was obtained. After 1 g of N, N-dimethylaniline was added to the obtained aqueous dispersion and sufficiently dissolved, 100 g of wood flour was added to the aqueous dispersion, and the mixture was stirred and dispersed. The mixture was poured into a 50 mm × 200 mm × 100 mm mold and vibrated. After defoaming, the mixture was cured at room temperature for 1 hour and then at 80 ° C. for 30 minutes. After the curing, the cured product was taken out from the mold and dried at 105 ° C. for 1 hour to obtain a porous cured product comprising a cured particle aggregate reinforced with organic fibers. The obtained cured product has a porosity of 34% by volume and an effective pore diameter of 0.6 μm.
Met. Table 1 shows the physical properties such as bending strength, specific gravity, and shrinkage of the cured porous material.

Comparative Example 1 A liquid unsaturated polyester resin (manufactured by Nippon Yupika Co., Ltd., "Yupika 6") was placed in a metal container having an inner diameter of 20 cm and a height of 30 cm.
510 "(specific gravity 1.10) 500 g was weighed, and 10 g of a commercially available benzoyl peroxide having a concentration of 50% by weight was used as a curing agent.
(1 g of a pure content with respect to 100 g of the resin) and 1 g of N, N-dimethylaniline were sufficiently dissolved, and then 100 g of wood flour was added and dispersed by stirring.
After being poured into a mold and subjected to vibration to remove bubbles, the mixture was cured at room temperature for 1 hour and then at 80 ° C. for 30 minutes. After the curing, the cured product was taken out from the mold and heated at 105 ° C. for 1 hour to obtain an organic fiber reinforced cured product. Table 1 shows the physical properties of the cured product such as bending strength, specific gravity, and shrinkage.

Comparative Example 2 The same procedure as in Example 2 was repeated except that the same O / W type aqueous dispersion as in Example 2 was used, and that no organic fiber powder was blended. A cured product was obtained. The obtained cured product had a porosity of 32% by volume and an effective pore diameter of 0.5 μm. Table 1 shows the physical properties such as bending strength, specific gravity, and shrinkage of the cured porous material.

Example 3 1 g of N, N-dimethylaniline was added to the same O / W type aqueous dispersion as in Example 1 and sufficiently dissolved, and then 100 g of wood flour and a chopped fiber having a fiber length of 3 mm were added to the aqueous dispersion. 25 g of glass was added and dispersed by stirring. This is 50mm ×
Pour into a 200 mm x 100 mm mold and apply vibration to degas and cure at room temperature for 1 hour, then cure at 80 ° C for 30 minutes, remove from mold after curing and dry at 105 ° C for 1 hour, glass fiber and organic fiber Cured product consisting of an aggregate of cured particles reinforced with high quality was obtained. The obtained cured product had a porosity of 31% by volume and an effective pore diameter of 0.6 μm. Table 1 shows the physical properties such as bending strength, specific gravity, and shrinkage of the cured porous material.

Example 4 1 g of N, N-dimethylaniline was added to the same O / W-type aqueous dispersion as in Example 1 and sufficiently dissolved. Then, 100 g of wood flour was added to the aqueous dispersion, and the mixture was stirred and dispersed. 450g /
After impregnating the glass chopped strand mat 3 plies of m ^2, by coating the surface with cellophane and polyester films and cured over a period of 30 minutes in a hot air oven at 80 ° C.. The cured product was dried at 105 ° C. for 1 hour to obtain a porous cured product composed of an aggregate of cured particles reinforced with organic fibers and glass fibers. The obtained cured product had a porosity of 28% by volume and an effective pore diameter of 0.6 μm. Table 1 shows the physical properties such as bending strength, specific gravity, and shrinkage of the cured porous material.

Example 5 A porous cured product consisting of a cured particle aggregate reinforced with organic fibers was obtained in the same manner as in Example 2 except that 300 g of wood flour was used. The obtained cured product had a porosity of 37% by volume and an effective pore diameter of 80 μm. Table 1 shows the physical properties such as bending strength, specific gravity, and shrinkage of the cured porous material.

[0050]

[Table 1] The “bending strength” was measured according to JIS K7203. The shrinkage ratio (Y) was obtained from the following formula from the size (A) of the mold and the size (B) of the molded product after curing.

[0051]

(Y)% = {(A) − (B)} / (A) × 100

[0052]

Industrial Applicability The present invention can effectively utilize organic fibrous powders such as wood chips, saw chips, wood chips and rice husk powder, and bagasse powder as sugarcane pulp discharged as industrial waste. The fibrous material is a porous material made of an aggregate having excellent strength and having continuous pores obtained by curing an O / W type aqueous dispersion, utilizing the characteristics of a lightweight porous material having a humidity control function. A cured product can be provided. Further, by using a liquid radical polymerization type thermosetting resin which has been provided with functions such as antibacterial property, antifungal property and deodorant property as an O / W type aqueous dispersion, a product with higher added value can be obtained. Can be. Also, O /
The strength of the cured product can be increased without impairing the porosity of the porous cured product having continuous pores obtained by curing the W-type aqueous dispersion, and applied to wall materials, microfiltration membranes, pottery mold materials, etc. In this case, the life of the product can be extended.

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Claims (7)

[Claims] 1. A cured particle aggregate reinforced by organic fibers having continuous pores, wherein resin particles obtained by curing an O / W type thermosetting resin aqueous dispersion in which organic fiber powder is dispersed are bonded. A porous cured product consisting of 2. An aqueous O / W type thermosetting resin dispersion comprising a liquid radical polymerization type thermosetting resin and water in a weight ratio of 9%.
The porous cured product according to claim 1, which is an O / W aqueous dispersion in which the resin particles are mixed at 0:10 to 60:40 and the resin particles are uniformly dispersed in an aqueous phase. 3. The O / W-type thermosetting resin aqueous dispersion in which the organic fiber powder is dispersed, comprises the organic fiber powder and the O / W type thermosetting resin aqueous dispersion in a weight ratio. 5: 95-50: 5
An O / W type aqueous dispersion obtained by mixing at 0.
Or the porous cured product according to claim 2. 4. The organic fiber powder is wood flour, chaff flour, wood chips,
The porous cured product according to claim 1, which is at least one selected from sawdust, bagasse powder, and wood chips. 5. The liquid radical polymerization type thermosetting resin is at least one selected from a liquid unsaturated polyester resin, a liquid epoxy (meth) acrylate resin, a liquid urethane (meth) acrylate resin, and a liquid (meth) acryl resin. The porous cured product according to claim 1, which is a seed. 6. An O / W in which a liquid radical polymerization type thermosetting resin is mixed with water, and the resin particles are uniformly dispersed in an aqueous phase.
The organic fiber powder is mixed and dispersed in the aqueous thermosetting resin dispersion, and the O / W thermosetting aqueous resin dispersion is cured at room temperature or under heating. Of producing a cured porous material. 7. An O / W-type thermosetting resin aqueous dispersion in which an organic fiber powder is dispersed is cured at room temperature or under heating in the presence of a reinforcing material. A method for producing a porous cured product.